Automated dough systems make production flow more efficient and are a safe robotics solution to bring into the factory.
The past few years have plainly shown how fragile the industry can be. Both the effects and aftermath of a global pandemic as well as worldwide conflicts resulted in challenges that initiated a steep learning process. Automation could answer a lot of these rising issues. The demand for even more automated, safe processes continues today. DIOSNA developed intelligent solutions that automate the area of pre-dough and kneading technology, while preserving product quality. Recently, the company focused its efforts on the automation of kneading processes through Automated Guided Vehicles (AGVs).
Automated solutions are based on a self-regulating process and designed for maximum flexibility, with possible variations considered for factors such as different recipes, individual dough resting times and cleaning options. Production facilities can include multiple dosing, mixing and/or discharge systems using DIOSNA’s solutions, depending on their size.
AGVs coming through!
Inside the plant, an automated transport system, i. e. an AGV solution, handles the dough. There are several ways to program and almost seamlessly monitor dosing and kneading. From the monitoring of kneading energy to the sequence of dosing and mixing processes, up to remote monitoring and remote maintenance, there are almost no limits to the possibilities of automation.
AGVs are highly flexible in automating dough production. They are already successfully used in various industries and have been continuously optimized in several aspects – regarding battery life, charging, speed and durability, for example. Room concepts can easily be adapted to current requirements. AGVs help process steps in dough production such as dosing, kneading, resting and tilting, to become location-independent. Capacity expansions can also be implemented quickly, as well as process sequences and timing.
Custom room layouts can be mapped out for AGVs to travel efficiently while handling dough production. While classic room concepts only allow maintenance and cleaning to be carried out during downtimes, the bowls can now also be cleaned in a separate room during production thanks to AGVs. They can approach dosing points flexibly. In addition to automating handling, they also contribute to a more efficient configuration of the space in the production area: AGVs with high-lift functions allow flexible, multi-level dough resting setups, both horizontally and vertically. In this way, considerably less space is required for dough resting sections.
Safe operations
AGVs navigate independently in spaces and transport raw materials, trays and dough resting boxes to the desired location within defined production sequences. For this purpose, they are equipped with state-of-the-art navigation systems and sensor technology. In addition, they are battery-powered and do not need rails or induction loops.
Safety and navigation features are implemented via well-protected laser scanners. They continuously monitor the movement area and navigate in the respective environment. In addition, there is a digital map of the operational environment in which the route is stored. In the event of an obstacle, the AGV stops or adapts its speed to the obstacle ahead.
AGVs can interact with several systems via a communication interface, as well as with their stations and a fleet management system. The latter is based on the DIOSNA production software, the Bowl Manager, which has been tried and tested for many years. The routes and the production sequences can be manually changed, at any time. This is also where the digital twin comes into play: DIOSNA simulates all processes and routes in advance so that there are no unpleasant surprises at the start of production.
In the future, further automated dough processing can also bring an automated interlocking of all production areas, in principle, connecting AGVs to the central fleet management system. Integrating other parts of the plant, such as packaging or loading, is also conceivable and would be a logical step.
